Pre-treatment

Paint School
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 Performance of a paint system

Good pre-treatment of the substrate

is a requirement to obtain

good performance of the paint system

Paint School
2
 Surface treatment may include
the following operations
• Steel work (Pre-blasting preparation)
• Removal of:
– Rust and mill scale
– Salt
– Grease, oil, dirt
– Old / unwanted paint
• Flattening of glossy paint
• Special pre-treatment of new aluminium
and galvanised surfaces
Paint School
3
 Maintenance
General surface treatment routine

• Plan the job thoroughly

• Remove grease, oil, salt, fouling
• Remove old, loose paint and
thick layers of rust
• Pre-treatment
• Remove dust (vacuum-cleaning)
• Apply paint

Paint School
4
 New buildings - New constructions
General surface treatment routine

• Plan the job thoroughly

• Steel work (sharp edges, rough welds etc.)
• Remove grease, oil and welding smoke
• Pre-treatment
• Remove dust (vacuum-cleaning)
• Painting

Paint School
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 Work to be carried out
in the cleaning shop

Remove prior to pre-treatment:

• Salt and soil: Clean water

• Oil - grease: Solvent with emulsifying agent

or alkaline cleaner

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6
 Surface cleanliness
Important to remove all contaminants
Surface preparation includes removal of:
• Salts
• Deposits of oil.
• Grease.
• Foreign matter (other contaminants)
This is achieved by
• UHPWJ.
• Steam cleaning
• Washing with detergent.
• Other methods agreed upon.

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 Cleaning procedure

• The surface shall be dry before application of cleaners

• Apply the cleaner from below and upwards
• Work systematically on all surfaces
• Let the cleaner react, normally 1-5 minutes
• Wash off from below and upwards
• Final rinse from above and down

Degreasing by wiping the surface with

solvents and rags is not recommended.
Leads to spreading of a thin film of oil over a wider area
and increases risk of fire / explosion

Paint School
8
 Cleaning procedure

• Apply the cleaner from

below and upwards
• Work systematically on all
surfaces
• Let the cleaner react,
normally 1-5 minutes
• Wash off from below and
upwards
• Final rinse from above and
down Pre-treatment / cleaning_container1

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 Degreasing side bottom with emulsifying
detergent to remove oil, grease etc.
• Should always be carried out before blast-cleaning
• The detergents must be removed by ”Low pressure
water cleaning, LPWC” (Around 250 - 300 bar)

CD 4932 no. 23

Paint School
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 Hosing down the side bottom after
blasting and applying a holding primer

• Hosing used to remove

loose dust and to remove
water soluble salts
• Ensure that fresh water is
used
• Some times necessary to
use “Low pressure water
cleaning, LPWC” to CD 4932 no. 24
remove grit adhering to
the holding primer

Paint School
11
 Removal of marine growth, salts and
loose paint by Low Pressure Washing
• Important to start the washing as soon as the ship is in the
dry-dock
• Usually pressures of minimum 250 bar at the nozzle
• Some of the Self Polishing Antifoulings may be removed

CD 4932 no. 25

Paint School
12
 The water quality can be
influenced by several factors

• Source:
- Drinking water
- Lake or river
- De-salination plants
• Addition of inhibitors
• Re-circulation
• Cleaning, filtering
• Certificates or analysis

Paint School
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 Water quality:
Potential sources and risks

Potential sources Potential paint failures

Salts
Osmotic
Contaminations blistering

Particles “Dust” after drying

Loss of adhesion

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 Equipment contaminating the surface
Oil contamination from grinder

Reasons may be: Must be removed prior

to surface preparation
• Oil leaking out of
equipment
• Equipment has been
stored with oil
• Lack of oil trap.
(Air from compressor
contains oil) CD 4932 no. 22

Paint School
20
 Flaking of Tar Epoxy

• Tar Epoxy system

• Flaking down to shop
primer
• Flaking due to poor
pre -treatment
• Remains of oil found
underneath the paint CD 4934 no. 57

Paint School
21
 Welding smoke and other contaminants
have not been removed prior to application
• Small steel units welded on to a deck construction
• Welding seams has been wire brushed
• Welding smoke will result in osmotic blistering

CD 4934 no. 99

Paint School
22
 Insufficient pre-treatment of welds and
removal of welding smoke
• Welding of new parts on areas already painted
• Weld smoke will result in osmotic blistering
• Better planning of the work is required

CD 4934 no. 100

Paint School
23
 Welding smoke is water soluble
and can only be removed by water
Area washed
Welding smoke with water

• Solvents will not

remove the welding
smoke completely
• If not removed,
osmotic blistering
may occur. CD 0589 no. 11

Paint School
24
 Blisters close to weld, probably due to
welding smoke remaining on the the steel
• Welding smoke is resoluble in water and will
create osmotic blistering
• Galvanic difference between steel plate and weld
may aggravate the attack

CD 4934 no. 79

Paint School
25
 Maintenance: Pre-treatment.
Selection of equipment and method
Tools and methods must be selected acc. to:
• Paint specification
• Area to be repaired
• Degree of damage on surface
• Existing paint system and pre-treatment
• Tools available
• Paint system to be applied
• Required lifetime
See also ISO 8501 - 2
Paint School
26
 Pre-treatment.
Recommended equipment
• Portable blast-cleaning unit
• Vacuum blasting equipment
• Air-powered grinding equipment
(Available with and without vacuum unit)
• Air-powered wire-brush
• Needle gun
(Available with and without vacuum unit)
• Air-powered chisel
• Scraper with interchangeable hard metal shears
Paint School
27
 Pre-treatment
Evaluation of methods
Blast cleaning Ideal
Power grinding Not as good as blast cleaning, but
best alternative.
Power wire-brushing Great risk of unwanted polishing.
Manual wire- brushing. Not recommended. Very poor.
Needle hammer Usable, but risk of unwanted rough
surface,
Power chiseling Good in combination with other
methods
Usable in combination with other
Manual scraping methods.

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28
 Pre-treatment
Production rates for various methods
Method Time * Achieved
min/m² standard
Blast cleaning 6  Sa 3
Power chiseling/wire brushing 9  St 2
Manual scraping / wire brushing 13  St 2
Power grinding 15  St 3
Manual scraping + power wire brushing 15  St 3
Power hammer / wire brushing 25  St 3
Power needle hammer / wire brushing 37  St 3
Water jetting, UHPWJ 6-8

* Only time required for the pre-treatment itself is given

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 Different
Power tool cleaning methods

• Reciprocating impact tools

• Rotary impact or scarifying tools
• Grinders or sanders

Available as:
• Portable, hand-held or “walk-behind” models.
• Vacuum assisted power tools, due to
environmental concerns

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 Reciprocating impact tools

• Needle scalers or guns

• Chipping guns (chisels)

• Scabblers.
– Small hand-held and “walk-behind” models.
– To break up heavy rust, mill scale and coatings.
Example: Rustibus

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 Equipment.
Hand and power tool cleaning
• Mechanical rotating wire brush
• Needle gun
• Hand Wire brush

CD 4932 no. 39

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 Power tool equipment.
A Needle gun consists of several needles
• Mostly used on areas difficult to access
• Gives a rough steel profile
• May be necessary to combine with other tools
to achieve a certain standard

CD 4932 no. 44

Paint School
33
 Needle gun is used on a support,
giving a rough steel profile
• The surface tolerant Mastic paints are
recommended for such substrates
• May be necessary to combine with other
tools to achieve a certain standard

CD 4932 no. 45

Paint School
34
 Rotary impact or scarifying tools

Equipment with rotating abrasive head

• Peening flaps (Roto-Peen)

- Creates a surface profile, 25 to 75 microns
• Rotary hammers - cutters
• Nylon non-woven abrasive wheels

Rotary impact tools is the

best choice for removing coatings

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35
 Hand held rotary impact tool
Roto - Peen
• Rotating abrasive head: Peening flaps (Roto-Peen)
• Creates a surface profile, 25 to 75 microns
• What about deep pits ?

Paint School
36
 Grinders and sanders

• Coated abrasive discs

- To remove paint, mill scale and rust
• Non-woven abrasive discs
- To remove paint and rust and for feathering of paint
• Wire brushes
- To remove loose rust (tends to polish surface)

Paint School
37
 Example on a disc:
Non-woven type
• Particularly used on
surfaces which can not be
blast-cleaned
• Excellent for feathering of
paint edges
• Will not polish the surface
as a mechanical wire brush
• Surface tolerant Mastic CD 4932 no. 50
paints are recommended on
such substrates

Paint School
38
 The tool can be used as grinder and sander,
depending on the disc. Here: Disc-sander

• Particularly used on
surfaces which can not
be blast-cleaned
• May be difficult to reach
narrow spaces and inside
corners
• Surface tolerant Mastic
paints are recommended CD 4932 no. 49
on such substrates

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39
 Pre-treatment of a tank.
Disc sanding of substrate
• Part of a tank
• Nice St 2 standard, almost St 3

CD 0589 no. 99

Paint School
40
 Manual and rotating wire brushes

• St 2 and St 3 can be
achieved
• Manual wire brushing is
heavy work
• Rotating wire brushes
speed up the production
rate
• Risk of having a polished
surface
• A polished substrate will
Pre-treatment: Wirebrush1
give poor adhesion to the
paint system
Paint School
41
 Wire brushing by hand to achieve given
standards according to ISO 8501
• Production rate is slow: High cost
• The quality is not as good as blast-cleaning or disc grinding
• The surface tolerant Mastic paints are recommended on wire
brushed surfaces

CD 4932 no. 40

Paint School
42
 Steel substrate treated by hand and
mechanical power tool cleaning equipment

Mechanical wire brush Hand wire brush,

approximately St 3 approximately St 2

CD 4932 no. 47

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43
 Hand wire brushed surfaces
Surfaces treated approximately to the
given standards according to ISO 8501

St 2 St 3

CD 4932 no. 41 CD 4932 no. 42

Paint School
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 Power tools.
Mechanical rotating wire brush
• Gives a faster production rate than the hand
operated wire brush
• Disadvantage: May give a polished surface if
used too extensively

CD 4932 no. 46

Paint School
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 Surface treated by Mechanical rotating
wire brush to the approx. standard St.3
• Observe the polished surface
• A polished surface will give a reduced
adhesion for the paint system

CD 4932 no. 48

Paint School
46
 Power tool cleaned tank.
Rotating wire brush
• The standard achieved is approximately St 2
• Some polishing effect has occurred

CD 4932 no. 51

Paint School
47
 Mechanical cleaning may
give unfavourable surfaces

Needle-hammer makes a rough

surface and deep indentations

Rotating wire brushes and disc-sanders

may give a polished surface

Paint School
48
 Selection of pre-treatment method
Mechanical cleaning vs. blast cleaning

• Blast cleaning is the best alternative.

• Use mechanical cleaning only when
blast cleaning is not possible

• Rotating wire brushes and disc-sanders

may give a polished surface

Paint School
49
 Surface preparation
Major advantages with blast cleaning

Correctly carried out, blast cleaning

gives an ideal surface for painting.

Blast cleaning is time saving

compared with mechanical cleaning

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50
 Pre-treatment
Illustration of various blasting methods

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51
 Dry blasting
Benefits and limitations
Advantages Disadvantages

• Surface remains dry • Does not remove salt

• Good anchor pattern • Does not remove oil
for paint • Creates dust
• No pre-rusting profile

Paint School
52
 Introduction to blast-cleaning

• Gives a good surface

profile
• Several blasting
standards can be
achieved
• Does not remove salts
from the substrate

Pre-treatment: Blast-cleaning1

Paint School
53
 Blast- cleaning equipment:
Medium size blast pot

• The pot is equipped with

remote control, operated
by the blast-cleaner
• Important to keep the lid
in place to avoid
contamination of the
abrasives CD 4932 no. 58
• Keep the abrasives dry

Paint School
54
 Blast- cleaning equipment.
Different compressors are on the market
• Must be able to provide a minimum
pressure of 7 kp/cm² at the nozzle.
• Oil traps and dehumidifier is required
to clean the air properly

CD 4932 no. 56

Paint School
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 Blast- cleaning equipment.
Dehumidifier

The capacity must be designed to fit the job

CD 4932 no. 57

Paint School
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 Blast hood and gloves

• Approved blast hood

• For open air blast cleaning
• Keep the hood clean
inside
• To be stored in a dust free
locker
• Gloves for blast-cleaning CD 4932 no. 54

Paint School
57
 Well equipped blast- cleaner

• Hood with visor

• Correct gloves for
blast-cleaning
• Protective overall
• Blast-cleaning nozzle
with a spot light
CD 4932 no.53

Paint School
58
 Blast-cleaning of a plate
taking place in a tent

• The plate was partly rusty

and partly covered by old
paint
• Blast-cleaned to Sa 2½
• Steel will turn black
rapidly if the abrasives
contain humidity
CD 4932 no. 59

Paint School
59
 Blast cleaning nozzle with light
• Handle to turn on and off the abrasive jet
• Light is mounted to improve the working
conditions for the blast cleaner

CD 4932 no. 55

Paint School
60
 Blast-cleaning in
open air, deck + structure
• Blast-cleaning in open air is not environmentally friendly:
High degree of pollution (dust)
• Creates a good anchor pattern for the paint
• Fast method and easy to reach all areas

CD 4932 no. 60

Paint School
61
 Surface preparation
Metallic or non-metallic abrasives.

Blast cleaning with Metallic or

Non-metallic abrasives to specified:

• Cleanliness acc. to ISO 8501 - 1 or 2

• Roughness acc. to ISO 8503

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62
 Abrasives
There are two main groups
1. Metallic abrasives
• Chilled iron grit (angular)
• High-carbon cast steel grit and shot (angular or round)
• Low-cast cast steel snot (round)
• Cut steel wire (cylindrical)

2. Mineral and slag abrasives

• Natural abrasives: Garnet, Olivine, Staurolite
• Slags: Copper refinery Nickel refinery
Coal furnace Fused aluminium oxide
Iron furnace
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 Metallic / mineral abrasives
Re-use
Metallic abrasives and Carborundum
(Al.oxide) can be recycled and are usually used
more than once.
For stationary plants

Mineral and slag abrasives are generally

used only once.
For open blast-cleaning

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 Shape of abrasives

Three main types of abrasives

Grit (Angular)

Shot (round)

Wire cut (cylindrical)

Paint School
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 Abrasives
Initial particle shape

Designation and initial

particle shape Symbol

Shot - round S

Grit - angular, irregular G

Cylindrical - sharp-edged C

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 Commonly used blast cleaning
abrasives for steel substrate preparation
Metallic (M) blast-cleaning abrasives
Initial particle
Type Abbreviation shape Comparator 1)

Cast iron Chilled M/CI G G

High-carbon M/HCS S or G S 2)
Cast steel

Low-carbon M/LCS S S

Cut steel - M/CW C S 2)

wire
1) Comparator to be used when assessing the resultant surface profile. The method for evaluating the surface profile by
comparator is described in ISO 8503-2.
2) Certain types of abrasive rapidly change their shape when used. As soon as this happens, the appearance of the surface
profile changes and becomes closer to that of the shot comparator

Paint School
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 Non-metallic, natural abrasives
for steel substrate preparation
ISO 8504-2:1992 (E)

Type Abbreviation Initial particle Comparator

shape

Silica sand N/Si

G G
Olivine sand N/OL

Starolite N/ST S G

Garnet N/GA G G

Paint School
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 Commonly used blast cleaning
abrasives for steel substrate preparation
Non-metallic (N) blast cleaning abrasives.
Synthetic
Iron furnace slag (Calcium silicate slags) N/FE G

Copper refinery slag (Ferrous silicate slags) N/CU G

Nickel refinery slag N/NI G

Coal furnace slag (Aluminium silicate slags) N/CS G

Fused aluminium oxide N/FA G

Paint School
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 Abrasives
Important points to check
Non - metallic abrasives

• Silica free : < 1 % free silica

• Particle size : Size and dispersion
ISO 11127-2
• Water soluble salter : 25mS/m= 250 µS/cm
• Hardness : Minimum 6 Moh
• No oil : Check with water

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 Reduction of coating
thickness above profile

Coating thickness, µm.

300 Mean thickness Thickness above profile

250

200

150

100

50

0 58 88 58 88 58 88
Roughness, µm

Paint School
71
 Recommendations
regarding blast cleaning

• Loose paint and rust to be removed prior to blast-cleaning

• Use correct ratio between air and abrasive
• Always use good quality abrasive
• Correct air-pressure 7 kg/cm² (100 psi) at the nozzle
4 - 4,5 kg/cm² is a waste of time

• Remove dust and spent abrasive residue with vacuum cleaner

or eventually dry, oil-free compressed air

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72
 Blast cleaning
Factors influencing the production rate

• Productivity is directly proportional to:

Pressure at Nozzle
Capacity of the air compressor

• Pressure at Nozzle 7 kg/cm² = 100% productivity

• Pressure at Nozzle 5,6 kg/cm² = 66% productivity
• Pressure at Nozzle 4,2 kg/cm² = 50% productivity

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 Blast - cleaning
Measure the air pressure at the nozzle
Pressure
gauge

Nozzle Nozzleholder

Air

Rubber hose

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 Blast cleaning: Effect of nozzle
pressure on cleaning rate.
Nozzle pressures, Kg / cm²

Cleaning time: 2 minutes Remaining

Source: Clemtex Ltd. Removed
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 Blast Cleaning
Rule of thumb: To avoid loss of pressure

The blast hose shall have an

opening which is 3-4 times
bigger than the orifice of the nozzle.

Hose opening Nozzle opening

3 - 4 times

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76
 Blast cleaning
Loss of pressure
Air pressure, bar
10 7 bar : Recommended
< 4 bar : Waste of time

2
0 50 100 150 200 250
Hose length, m
Hose diameter 3/4" 1" 1 1/4" 3/4" 1" 1 1/4"

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 Blast cleaning: Venturi nozzles increase
the speed of the abrasives

Standard nozzle abrasive speed: 300 Km/h at 7 bar

. . .. .
. . ...... ...
.
Venturi nozzle abrasive speed: 700 km/h at 7 bar

. . ..
. . . .... . ...
. .

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 Blast cleaning
Impact damages may destroy overlapping zone

Corroded area. Subsequent spot blasting

Solid coating

Originally
corroded area

Impact by abrasives
Feathered required

(SOURCE: Munger, C.G. Practical aspects of Coating Repair.

Materials Performance, Vol. 19, No 2 p. 46 (1980)

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 Corrosion due to
recoil from blast-cleaning
• Blast-cleaning has been carried out on the opposite side.
• Recoil of grit has damaged the intact paint
• Corrosion develops after a short period of time

CD 4930 no. 87

Paint School
80
 Spot blasting might be a cause
for future paint damages
• Blast-cleaning destroys
the edges of the intact
paint film around the
damage
• This results in poor
adhesion
• Damaged paint edges
must be feathered prior
to application of the
new paint
Pre-treatment: Spotblasting1

Paint School
81
 Feathering of overlapping zones

Sharp edges should be feathered prior to painting

Before feathering After feathering

Paint

Steel Steel

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82
 Blast cleaning
Abrasives will damage the coating
Cracks due to direct
impact by abrasives 3-Coat paint

Area require
feathering
Steel
Area with Corroded and
reduced adhesion blast cleaned

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 Blast cleaning
Abrasives will damage the coating
Impact of abrasive Star crack areas 3-coat paint system

Areas with reduced adhesion

Steel

May be caused by direct impact

or rebounding abrasives (ricochet)

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 Blast cleaning
Correct and incorrect sweep blasting
Abrasives approx. 0.5 mm
Pressure approx 2-3 kg / sqcm

Star cracks

Often abrasives of
0.2 - 1.4 mm and too
high pressure is used

Paint School
85
 Spot blasted ship side.
Many small spots gives many loose edges.
• Every loose edge have to be feathered.
• A loose edges will often result in corrosion.
• Steel suffering severe corrosion and pittings will
turn black shortly after blasting

CD 4930 no. 81

Paint School
86
 Blast-cleaning of welding seams
and damaged shop primer to Sa 2 ½
• The remaining shop primer will be accepted as
Sa 2 ½ if not anything else is specified
• Sweep blasting of remaining shop primer may be
required to have sufficient anchor pattern

CD 4932 no. 65

Paint School
87
 Spot-blasting (upgrading) of the
paint system. Lots of loose edges
• Spot blasting of rusted areas
• Sweep blasting of the remaining old paint
• Cheap treatment, which is usually not recommended:
Corrosion will develop from loose edges

Bare steel

Remaining
primer CD 4932 no. 66
Antifouling

Paint School
88
 Corrosion has taken place
Almost the total area has been spot blasted

• Spot blasting in this way result in many loose

edges that needs to be feathered
• Recommendation: Blast - clean larger areas

Top coat

Bare steel CD 4932 no. 67

Antifouling

Paint School
89
 Only the corroded parts of the
area have been spot blasted (1 of 2)
• This kind of blasting is not recommended
• It was requested to blast larger areas to reduce
the number of loose edges. (See next photo)

CD 4932 no. 68

Paint School
90
 Originally spot blasted areas gives
pitted steel after further blasting. (2 of 2)

• Pitted steel turn black due

to salts in the pittings
• The dark spots must be
washed with water to
remove salts and then
reblasted
• Area originally covered by
intact paint show no pitting
CD 4932 no. 69
and will remain grey and
keeps the standard for a
longer period of time )

Paint School
91
 Loose edges resulting from spot-
blasting carried out some time ago
• Edges has not been feathered prior to application of the paint
• The edges are weak points in the paint film
• Corrosion attack initiates on such areas

CD 4934 no. 80

Paint School
92
 Spot blasted underwater hull
• Thick old paint creates sharp edges
• Loose edges has lifted
• Blistering, flaking and corrosion has developed
shortly after maintenance

CD 4930 no. 84

Paint School
93
 Surfaces blast - cleaned
to various standards
Plate was originally partly rusty and partly painted.
Blast-cleaned approximately to the given standards
Sa 1 Sa 2 Sa 2 ½

CD 4932 no. 61

CD 4932 no. 62 CD 4932 no. 63

Paint School
94
 Test areas are put up on a structure to
agree on the blasting standard
• Test areas are often put up on the site to make sure
that the standard specified is obtained
• Agreement before the work starts will help to avoid
later discussions and disagreements

CD 4932 no. 76

Paint School
95
 Maintenance blast-cleaning
of a ship’s side in a dry-dock
• Full blast-cleaning from top side and down is required
• Blast-cleaning to the standard Sa 2 ½

CD 4932 no. 64

Paint School
96
 Pitted and corroded steel
after blast-cleaning

• Corrosion has been going

on too long
• The steel shows deep
pits, sharp edges and is
very uneven
• Difficult for a paint
system to give CD 4930 no. 82
satisfactory protection

Paint School
97
 Handy vacuum blasting equipment
for small repairs
• Several types of nozzles
can be used. Makes it EDUCT-O-MATIC
possible to obtain all
steel profiles.
• All types of abrasives
can be used
• Possible to recycle the
abrasives
CD 4932 no. 70
• Slow production rate
• Environmentally
friendly

Paint School
98
 Vacuum blasting equipment
for large, flat areas
• High investment costs
• Heavy equipment
• Environmentally friendly
• Soft profile due to recycling of the abrasives (Steel shot)

CD 4932 no. 71

Paint School
99
 Blast cleaning
How to protect blasted areas

• Blast clean limited areas at a time

• Remove all dust and abrasive residue
• Protect with a quick drying
holding / blast primer
• Continue treating the next area

Paint School
100
 Untreated or poorly treated welds
suffering early corrosion
• Probably wire brushed without washing with fresh water
• In addition, the paint film was too thin

CD 4930 no. 79

Paint School
101
 Corrosion due to back burning

• Hot work on the back side of the painted surface

• Premature rust due to: Insufficient pre-treatment
and paint application

CD 4930 no. 73

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102
 Scaffoldings must be completely
cleaned from grit before application
Grit may blow or fall into the wet paint and give a rough
surface and, at a later stage, initiation of corrosion

CD 4932 no. 77

Paint School
103
 Scaffoldings have not been cleaned well
and grit contaminate the paint film
• The surface is not acceptable
• Weak points in the film will lead to early corrosion
• The adhesion is reduced

CD 4932 no. 78

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 Surface has not been well cleaned
Overpainting grit or foreign matters
• Weak point in paint film
• Entrapped air
• Less adhesion
• Corrosion will develop rapidly

CD 4932 no. 79

Paint School
105
 Poor cleaning of ballast tanks

• Abrasives remaining from blast cleaning

• 300 m Coal Tar Epoxy
• Blistering and rust penetration after 10 months of exposure

Cd 0589 nr 18

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 Slurry and wet blasting
Benefits and limitations
Advantages Disadvantages

• Surface profile is • Flash rust may

achieved develop on surface
• Removes salt
• Creates no dust.

Paint School
107
 Wet Blasting
Mixture of water and sand

• No, or very limited,

formation of dust
• Flash rust may form on
the steel structure
• May be necessary to
remove remaining
abrasives by hosing down.
CD 4932 no. 26

Paint School
108
 Chloride concentration on
surfaces after pre-treatment.
Chloride cons. (mg / m2 )
140
120 Hot-rolled steel (Rust grade A)
100
80 Pitted steel (Long term exposure)
60
40
20
0
Untreated Dry Wet Wet Surf-
surface Blasting blasting blasting blasting
1.6 l/min. 7 l/min.

Paint School
109
 Water jetting

• Water-jetting is an alternative
to blast cleaning.

• Water-jetting has:
- Environmental
- Technical
- Practical
………….benefits and drawbacks

Paint School
110
 An introduction to Ultra High
Pressure Water Jetting (UHPWJ)
• High water pressures
(up to 2500 bar)
• Manual equipment:
Heavy work
• Different types of
nozzles can be included
in one rotating nozzle
unit
• Removes water soluble
salts
Pre-treatment: Wj_equipment1

Paint School
111
 Water-jetting
NACE No. 5 / SSPC SP. 12
• Low Pressure Water Cleaning (LPWC)
Less than 34 MPa (340 bar/5 000 p.s.i.)
• High Pressure Water Cleaning (HPWC)
From 34 to 70 MPa
(340 to 680 bar/5 000 to 10 000 p.s.i.)
• High Pressure Water Jetting (HPWJ)
From 70 to 170 MPa
(680 to 1 700 bar/10 000 to 25 000 p.s.i.)
• Ultra-High Pressure Water Jetting (UHPWJ)
Above 170 MPa (1700 bar/25 000 p.s.i.)

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 Water Cleaning is classified according
to the pressure (NACE / SSPC)

Pressure, bar Classification

Below 340 LPWC
340 - 680 HPWC

680 - 1700 HPWJ

Above 1700 UHPWJ

NB - Pressure at nozzle !
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 Visual surface preparation
SSPC and NACE definitions.
Condition Description of Surface (when viewed without magnification)

WJ-1 Free of all previously existing visible rust, coatings, mill scale, and
foreign matter and have a matt metal finish.

WJ-2 Cleaned to a matt finish with at least 95 % of the surface area free of all
previously existing visible residues. Remaining 5% containing only randomly
dispersed stains of rust, coatings, and foreign matter.

WJ-3 Cleaned to a matt finish with at least two-thirds of the surface free of all
visible residues (except mill scale). Remaining one-third containing only
randomly dispersed stains of previously existing rust, coatings, and foreign
matter.

WJ-4 All loose rust, loose mill scale, and loose coatings uniformly removed.

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 Non-visual surface preparation
SSPC and NACE definitions
Condition Description of Surface
• SC-1: Free of all detectable levels of contaminants as determined using
available field test equipment with sensitivity approximating laboratory test
equipment. For purposes of this standard, contaminants are water-soluble
Chlorides, Iron-soluble salts, and Sulphates.

• SC-2: Less than 7 µg/cm² Chloride contaminants, less than 10 µg/cm² of

soluble Ferrous ion levels, and less than 17 µg/cm² of Sulphate
contaminants as verified by field or laboratory analysis using reliable,
reproducible test equipment.

• SC-3: Less than 50 µg/cm² Chloride and Sulphate contaminants as verified

by field or laboratory analysis using reliable, reproducible test equipment.

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 UHPWJ
Definition: Standard jetting water
NACE No 5 /SSPC - SP 12:

• Water of sufficient purity and quality.

• Not impose additional contaminants on the
surface.
• Not containing sediments or impurities destructive
to the proper functioning of the equipment.

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 Why Water-jetting ?

• The Environment is affected (to

some degree) by all types of surface
preparation.
• Water jetting has many technical and
environmental advantages, but also
some drawbacks.

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 Water-jetting
Advantages
• Salt level on steel surface drastically reduced.
• No dust produced.
• No grit cost (water is usually cheaper).
Grit blasting uses 55 kg/m², costing £ 63,-/ton = 3,46/m².
Ultra High Pressure Water Jetting, UHPWJ needs 130 l/m²,
costing £ 0,80/ton = £ 0,10/m²).
• Close working of other trades possible.
• Abrasives can be introduced if improved surface profile is
required.
• Lower noise level than with grit blasting.

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 UHPWJ
Major technical advantage

Removes water soluble salts

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 Formation of blisters as a function of salt
concentration on substrate (1 of 2)

Salt: 0 mg/ m² Salt: 60 mg/ m²

Film: 150 microns Film: 150 microns

CD-1183 no.89 CD-1183 no.90

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 Formation of blisters as a function of salt
concentration on substrate (2 of 2)

Salt: 100 mg/ m² Salt: 200 mg/m²

Film: 150 microns Film: 150 microns

CD-1183 no.92
CD-1183 no.91

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 UHPWJ - Factors influencing the
performance of the paint system

• Pressure
• Amount of water used
•Cleanliness
• Quality of water
•Adhesion
• Degree of flash rust
• Salts and contamination

• Surface roughness
• Type and condition of equipment
• Workmanship
• Properties of the paint film

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 Water-jetting
Disadvantages:

• Flash Rusting.
• Capital cost of equipment.
• No additional surface roughness.
• Equipment may be “bulky” for
narrow spaces (ballast tanks).
• Water quality and availability
• Water freeze below 0°C

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 Water jetting equipment suspended
in a wire connected to a reel

• Less exhausting for the

operator: Increased
production rate
• This unit is designed to
clean flat areas
• Four rotating nozzles
CD 4932 no. 36

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 UHPWJ Rotating nozzle
with four individual nozzles
• A brush is placed at the circumference to
collect water and debris from the substrate
• Vacuum unit
• May be suspended

CD 4932 no. 38

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 Rotating nozzles must be
designed to fit the purpose
Rotating nozzle
Here : 6 nozzles

Wide water beam:

For large areas

Narrow water beam:

For deep pits

NOTE !
The nozzle must be dimensioned not to exceed
the maximum available amount of water.

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 High Pressure Water Jetting of 2 pipes
Zinc reduces the formation of flash rust
Comparing 2 pipes
1. Zinc shop primer
2. Iron oxide shop primer

Result:
Zinc: No flash rust

Iron: Flash rust CD 4932 no. 30

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 The Bresle method.
ISO 8502 - 6 and ISO 8502 - 9

A method for determining the level of

water soluble salts on a steel surface

The Bresle method

This is a quantitative test

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 How to measure the
salt level on a surface
• Water soluble salts will be
removed by water jetting
• Here: The substrate is
cleaned at a pressure of
2000 bar
• Salt level is measured by
the Bresle method
• Dissolve the salt inside the
frame of the patch
• Measure the conductivity
of the water sample Pre-treatment: Wj_saltlevel1

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 Calculation of salt level
on the substrate

Formula: (L2 - L1) x 6 = mg salt per m2

L2 = µS after cleaning

L1 = µS before cleaning

Water sample, ml.: 10 15 20 50

Constant in formula: 4 6 8 20

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 Water-jetting removes salt
An example carried out
• 17 litres of water/min at 2500 bar
• Rotating Nozzles
• Removal Rate: 10 - 15 sq.m hour
• (Grit Blasting: 10 sq.m hour)
• Water Consumption: 50 - 150 ltrs./sq.m.
• Surface temp. increase: 10-15 °C

Salt levels:
Badly corroded area after Water-jetting 10 mg/m²
Badly corroded area after Grit Blasting 70 mg/m²

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 Water jetting
Effect of pressure

• Higher pressure gives an

improved cleaning of the
substrate
• The productivity will
increase
• Please observe that
removal of salt require lots
of water and is not pressure
dependent Pre-treatment: Wj_pressurre1

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 Formation of flash rust is less than
expected. The steel temperature increases.

• Flash rust formation

depends on several
factors
• Some times the degree
of flash rust is less than
expected
• The water jet supplies
energy to the steel
• The temperature
increases and the
evaporation of water
Pre-treatment: Wj_flashrust1
will be quicker
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 Equipment for UHPWJ
Here: Water pressure up to 2000 bar
• Rotating nozzle ensures less recoil
• Various nozzle sizes can be used
• Up to 6 individual nozzles can be mounted
in one rotating nozzle

CD 4932 no. 32

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 Short water jetting gun,
only 40 cm long
• Capacity 2000 Bar and 20 l / min
• Almost no recoil. Is easily operated with only one hand
• Rotating nozzle consisting of several individual nozzles

In many places not

allowed:
A short gun
represents a
larger hazard for the CD 4932 no. 34
operator

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 Rotating nozzle for UHPWJ
equipment. Up to 2500 bar
• Nozzles can be tailor made to fit the
substrate to be cleaned
• Angle and capacity of the nozzles can be varied

CD 4932 no. 35

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 High Pressure Water Jetting: 1500 - 1700
bar. Formation of flash rust (J.G.3.)
• Surface prior to jetting:
Old paint and Rusty steel
• Substrate achieved a surface standard
comparable to Sa 2

CD 4932 no. 31

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 Flash rust may develop
on UHPWJ surfaces

Limits for acceptable levels are not well

documented

Still: Flash rust is preferred to moisture /

Water

Flash rust will make inspection more difficult

Removal of salt reduces extent of flash rust

formation.
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 UHPWJ:
A good result depends on the workmanship

Work procedures / Specifications

Equipment
Experience and qualification
Inspection and control
Standards and acceptance criteria

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 UHPWJ
Experience up to now

• Short term properties on jetted

surfaces is well documented.
• Long term properties ?
– Substrate with flash rust (degree of rust ?)
– Adhesion
– Under cutting corrosion from coating defect
• Result / lifetime depends on the quality of the
work (Good workmanship).

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 Water jetting safety booths.
Use approved types only
• UHPWJ involves pressures exceeding 1700 Bar
• Yellow type - approved
• Black type - not approved

CD 4932 no. 28

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 Water jetting safety booths.
Photo of boots after testing at 2000 bar
• Testing: Pointing water jet at the shoes
• Yellow - approved type
• Black - not approved type

CD 4932 no. 29

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 UHPWJ
Safety

UHPWJ involves water jets

of very high pressure

• Education and training is required

• Learn how to operate equipment
• Always use adequate personal protection.
• Check equipment regularly
• A minimum length of 75 cm for hand held
lances is quite often a requirement

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 UHPWJ
Equipment for personal protection

• Helmet with visor

• Ear protection
- (Noise: Up to 130 decibel)
• Protective suit (and rain coat)
• Gloves
• Protective shoes
• Fresh air supply in confined spaces
- Risk of drowning in dense water mist

Always use approved equipment

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 Blast-cleaning and water jetting
represent a safety risk for the operator

• High pressures are

involved
• Never point the guns at
yourself or any other
nearby person
• Always use approved
equipment
• Unapproved equipment
may give inadequate
protection
Video: She_glove_and_booth1

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 UHPWJ
Compatible types of paint

• Paint type must be compatible with the

condition of the surface.
• Water jetted surfaces require surface tolerant
products due to:
- Uneven surfaces caused by corrosion
- Possibility for flash rust on the surface.
• This limits the applicable paint types
• Recommended type:
- Modified epoxy (Epoxy Mastics)
- Reason: Surface tolerant and High Build

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 Pre-treatment of Stainless steel

• Degreasing and washing

• Sweep blasting with non-metallic abrasive
• Abrading through other means, e.g.
mechanical tools, emery paper etc

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 Pre-treatment of Aluminium
• Degreasing and washing
• Sweep blasting with non-metallic abrasive
or
• Abrading through other means, e.g.
mechanical tools, emery paper etc
or
• Washing with a strong alkaline cleaner
followed by washing with clean water
or
• Wash primer (Not in combination with
Epoxy paint)
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